Download Alto-Shaam QC-40 Operating instructions

®
INSTALLATION
and
MAINTENANCE
MANUAL
QC-40
P R O C E S S I N G R E F R I G E R AT I O N S Y S T E M
W 1 6 4 N 9 2 2 1 W a t e r S t r e e t ● P. O . B o x 4 5 0
●
PHONE: (262)251-3800
(800)558-8744 U . S . A ./ C A N A DA
●
Menomonee Falls, Wisconsin 53052-0450 ● U.S.A.
●
FAX: (262)251-7067
(800)329-8744 U . S . A .
www.alto-shaam.com
#8402 - 5/03A
quickchiller Processing Refrigeration System
®
I N S TA L L AT I O N & M A I N T E N A N C E M A N U A L
Ta b l e o f C o n t e n t s - Q C - 4 0
1.0 GENERAL INFORMATION & INSTALLATION
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Scope of the Manual . . . . . . . . . . . . . . . . . .
1.3 Equipment Description . . . . . . . . . . . . . . . .
1.4 Equipment Supplied . . . . . . . . . . . . . . . . . .
1.5 Receipt and Unpacking . . . . . . . . . . . . . . . .
1.6 Installation . . . . . . . . . . . . . . . . . . . . . . . . .
1.6.1 — Site Selection. . . . . . . . . . . . . . . . . .
1.6.2 — Installation Requirements . . . . . . . .
1.6.3 — Door Seal . . . . . . . . . . . . . . . . . . . .
1.6.4 — Drain Hose . . . . . . . . . . . . . . . . . . .
1.6.5 — Remote Condensing Unit Guidelines
1.6.6 — Electrical . . . . . . . . . . . . . . . . . . . . .
1.6.8 — Power . . . . . . . . . . . . . . . . . . . . . . .
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2.0 CONTROL SET-UP & OPERATION
page
2.1 Start-Up Procedures . . . . . . . . . . . . . . . . . . . . 6
2.2 Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2.3 Start-Up Test . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Sequence of Control Operation . . . . . . . . . . . . 7
2.5 Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5.1 — Hold Mode . . . . . . . . . . . . . . . . . . . . . 9
2.5.2 — Open Door . . . . . . . . . . . . . . . . . . . . . 9
2.6 Operation With Food Product . . . . . . . . . . . . . 9
2.7 Shut-Down Procedure . . . . . . . . . . . . . . . . . . 10
2.8 Hardware Notes . . . . . . . . . . . . . . . . . . . . . . 10
3.0 CONTROL & COMPONENT
PARTS IDENTIFICATION
3.1 Control Parts List. . . . . . . . . . . .
3.2 Electrical Parts List . . . . . . . . . .
3.3 Probes and Sensors . . . . . . . . . .
3.4 Parts Not Shown on Views . . . . .
— Refrigeration Parts List
— Cabinet and Miscellaneous Parts
5.0 CLEANING & MAINTENANCE
5.1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.2
Interior Cleaning . . . . . . . . . . . . . . . . . . . . . . 23
5.3
Exterior Cleaning . . . . . . . . . . . . . . . . . . . . . . 23
5.4
Slide-In Pan Rack & Rack Track . . . . . . . . . . . 23
5.5
Compressor & Condenser Maintenance . . . . . 23
TRANSPORTATION DAMAGE & CLAIMS
24
ALTO-SHAAM LIMITED WARRANTY
24
L I S T O F TA B L E S
page
1.0
LEADING PARTICULARS
2.4.1 CONTROL MODE OVERVIEW
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4.0 DIAGNOSTIC & REPAIR PROCEDURE
4.1 Introduction . . . . . . . . . . . . . . . . .
4.2 Control Diagnosis . . . . . . . . . . . . .
4.2.1 — Solenoid Check . . . . . . . . .
4.2.2 — Fan Check . . . . . . . . . . . . .
4.2.3 — Defrost Heater Check . . . . .
4.2.4 — Condensing Unit Check . . .
4.2.5 — Cooling Test . . . . . . . . . . . .
4.3 Condensing Units . . . . . . . . . . . . .
4.3.1 — Control Cable Connections .
4.3.2 — Condensing Unit Fuses . . . .
4.4 Fans, Heaters, Solenoids . . . . . . . .
4.5 Trouble Shooting Guidelines
— CONTROL . . . . . . . . . . . . . . . . .
— REFRIGERATION . . . . . . . . . . .
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1
8
2.4.2 EVAPORATOR FAN, DOOR HEATER &
CONDENSING UNIT OPERATION
AT-A-GLANCE CONTROL SETTINGS
8
11
L I S T O F I L L U S T R AT I O N S
page
FIG. 1.0
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page
QUICKCHILLER ASSEMBLY DRAWING
2
FIG. 1.4.1 RACK MANAGEMENT TROLLEY SYSTEM
3a
FIG. 1.4.2 RACK MANAGEMENT TROLLEY SYSTEM
3b
FIG. 1.4.3 RACK MANAGEMENT TROLLEY SYSTEM
3c
FIG. 1.6.4 PLUMBING
4
FIG. 1.6.6 ELECTRICAL LOCATION
5
FIG. 2.1.3 MICROPROCESSOR CONTROL
7
FIG. 2.8
CPU BOARD DIP SWITCH LOCATION
10
FIG. 3.1
CPU ENCLOSURE
13
FIG. 3.2.1 COMPONENT BOX ASSEMBLY
14
FIG. 4.5.1 RELAY BOARD
20
ELECTRICAL SCHEMATIC
21
REFRIGERATION SCHEMATIC
22
. . . . . . . . 18
. . . . . . . . 19
For complete operational instructions see
Q u i c k c h i l l e r ™ O p e r a t i n g P r o c e d u r e G u i d e — Publication Number 265
—I—
1.0 — General Information and Installation
1.1 INTRODUCTION
1.4 EQUIPMENT SUPPLIED
The Alto-Shaam® Quickchiller is a processing
refrigeration system designed to rapidly and
uniformly cool hot foods through the "chilling danger
zone" of 140° to 40°F (60° to 4°C) in two hours or less.
Fast cooling minimizes microbial activity, thereby
controlling quality and sanitation in prepared foods.
As a result, a five-day storage life is achieved.
The Quickchiller, along with the interior racktrack and slide-in pan rack is shipped from the
factory fully assembled. The complete assembly
is palletized and crated to minimize the
possibility of damage in shipping and storage.
The optional rack trolley, to mobilize the
Quickchiller slide-in pan rack, is shipped
separately.
Chill processing stops all cooking activity. This
enables the operator to accelerate additional
preparation sequences. Chilling also enhances the
freshly prepared characteristics of foods.
Ta b l e 1 . 0 - L E A D I N G PA R T I C U L A R S
Distributor: Alto-Shaam, Inc.
Quick chill processing of prepared foods provides a
means to build refrigerated inventories of meals in
individual portions and bulk quantities. Chilled
inventories can be withdrawn and reheated as
required. For complete, comprehensive operating
instructions, refer to booklet No. 265, Quickchiller
Operating Procedure Guidelines.
Address: W164 N9221 Water Street
P.O. Box 450
Menomonee Falls, WI 53052-0450,
U.S.A.
Type: Quickchiller®
Processing Refrigeration System
1.2 SCOPE OF THE MANUAL
Model QC-40
(Self-Contained and Remote)
This technical manual provides sufficient
information for installation and general
maintenance of this equipment.
Purpose: To effectively speed the chilling
process of recently prepared,
1.3 EQUIPMENT DESCRIPTION
hot foods.
The unit consists of the following parts:
a. Storage Compartment: The insulated food
storage compartment is clear storage area. This
area is dedicated to the rapid decrease of recently
cooked foods and as a short-term refrigerated
storage area.
b. Door: Access to the storage compartment is
through a hinge-mounted insulated door. The door
includes a full gasket to provide a tight seal.
Power Supply: QC-40 (Self-Contained and Remote)
208/230VAC
60 Hz, 1ph
30 AMP CIRCUIT RECOMMENDED
Refrigeration: 13910 BTU/HR (max.)
Drain Requirements: The chiller is furnished with a
drain line which runs from the
evaporator coil and exits the
c. Evaporator Coil: The evaporator coil is located in
the storage compartment and functions as the
distribution point for the cold air associated with
the refrigeration system.
d. Cabinet: The cabinet is the enclosure consisting of
the above items.
bottom of the chiller. There is no
plumbing required.
Water Requirements: None (unless unit is water-cooled)
Miscellaneous: QC-40 (Self-Contained)
e. Condensing Unit Compartment: This area
contains the condensing unit(s). Remote systems
utilize a condensing unit located elsewhere within
or external to the facility.
Net Weight: 650 lb. (295 kg)
f. Electrical Enclosure: The electrical enclosure
includes the fuses, relays, and relay board.
Net Weight: 600 lb (272 kg)
#8402 QC-40
INSTALLATION
Ship Weight: 825 lb. (374 kg)
QC-40 (Remote)
Ship Weight: 775 lb (351 kg)
&
MAINTENANCE MANUAL
PG .
1
1.0 — General Information and Installation
ELEC. BOX
19-1/4"
1"
(25mm)
ELECTRICAL
ENCLOSURE
39-3/4" (1010mm)
37-1/4" (946mm)
35" (889mm)
(489mm)
1/2 HP
1 HP
CIRCUIT
BREAKER
– TOP VIEW –
38-1/2" (978mm)
30-3/8" (772mm)
CPU
Enclosure
6" (152mm)
36-3/4" (933mm)
‹
(597mm)
70-1/4" (1784mm)
2-1/4" (57mm)
23-1/2"
‹
FIG. 1.0
ITEM:
Quickchiller Assembly Drawing
MODEL: QC-40 Quickchiller™ Processing Refrigeration System
DATE:
05/03
SCALE:
N.T.S.
DWN BY:
LRL
®
MENOMONEE FALLS, WISCONSIN 53051, U.S.A.
PG .
2
#8402 QC-40
INSTALLATION
&
MAINTENANCE MANUAL
1.0 — General Information and Installation
1.5 RECEIPT AND UNPACKING
Upon receipt of the Alto-Shaam ® Quickchiller,
note any crate markings for special instructions
and check for crate damage. IMMEDIATELY
notify the carrier if there appears to be damage
to the equipment. The chiller is shipped from
the factory, securely fastened to a single shipping
pallet and protected by an external wrapping.
Carefully remove all external wrappings and
other protective coverings. If all is in order,
discard crating materials.
1.6 INSTALLATION
After leveling the cabinet, check the height
relationship of the ( OPTIONAL ) base trolley to
the slide-in pan rack inside the cabinet.
Adjust Quickchiller height as needed.
1.6.3 DOOR SEAL: Check the door gasket to make
certain it is sealing properly and that the
gasket provides an even and positive seal
around the entire door frame.
1.6.4 DRAIN HOSE: Unit includes an evaporative
base condensing unit. No plumbing is
required for condensate drainage. Refer to
Section 5.5 for cleaning instructions.
AAAAAAA
Prior to moving the Quickchiller to the
installation site, check the dimensions of doors,
passageways, and ceiling heights in the areas
through which the cabinet must be moved. Also
check the turning radius if the cabinet must be
moved around an existing structure.
FIG. 1.6.4 PLUMBING: MODEL QC-40
DRAIN
Note: In certain instances, it may be necessary
to remove doors and door hardware to
negotiate tight spaces.
1.6.1 SITE SELECTION: Position the Quickchiller
to allow sufficient air ventilation through the
condensing unit(s). Rear of unit should be no
closer than 6" to any wall or structure.
1.6.5 REMOTE CONDENSING UNIT GUIDELINES
Installation must be performed by certified
and authorized refrigeration service
personnel or warranty is void.
Interconnecting liquid and suction line sizes
for Quickchillers are as follows:
Avoid installing the chiller immediately
adjacent to fryers, charbroilers, or any other
equipment producing grease laden air; heat
producing equipment such as ovens and
ranges; and steam discharging equipment
such as steamer ovens and kettles.
LIQUID LINE
SIZE
SUCTION LINE
SIZE
QC-40R
QC-50R
Both
Large
Small
Both
1/4"
3/8"
3/8"
3/8"
3/8"
7/8"
5/8"
7/8"
Separation distance between the Quickchiller
and condensing units must not exceed fifty
(50) feet with zero (0) lift. Liquid line lift
(Quickchiller elevation above that of
condensing unit) reduces allowable
separation distance significantly.
1.6.2. INSTALLATION REQUIREMENTS: Install
the Quickchiller on smooth and level floor
surface. The unit must be leveled with the
SLIDE-IN PAN RACK inside the cabinet.
Use the adjustable cabinet legs to level the
unit.
Satisfactory refrigerating capacity is possible
with condenser entering air temperatures
below 115°F.
Insulate both suction and liquid lines.
Adjust from front-to-back and from side-toside to evenly distribute the cabinet weight
and avoid pulling the cabinet alignment out
of square.
INSTALLATION
CONDENSING
UNIT
QC-100R
Allow sufficient front clearance for
serviceability and for easy maneuvering of
food trolleys in and out of the cabinet.
#8402 QC-40
QUICKCHILLER
MODEL
Suction lines should be pitched down 1/2" in
10' of run in the direction of flow. A "P" trap
(closely) connected) is required for vertical
risers greater than 3 feet in elevation.
&
MAINTENANCE MANUAL
PG .
3
1.0 — General Information and Installation
1.6.6 ELECTRICAL: The Quickchiller must be
installed by a qualified electrician. This
appliance must be branch circuit protected
with proper ampacities in accordance with
the wiring diagram located in this manual.
In the U.S.A., the chiller must be properly
grounded in accordance with the National
Electrical Code and applicable local codes.
19-1/4"
1/2 HP
Failure to correctly connect the control
transformer will result in erratic control
operation and control damage.
ELEC. BOX
1.6.10 For supply voltage less than 218 Volts, proceed
as follows. Remove the front grille and slide
the left side condensing unit fully forward.
Remove the electrical enclosure cover. Locate
the control transformer. Disconnect the orange
(240V) transformer wire from the terminal
block. Remove the wire nut from the red (208V)
transformer wire and install wire nut to the end
of the orange wire. Connect the red wire (208V)
to the terminal block. Restore electrical
enclosure cover, condensing unit and grille.
(489mm)
ELECTRICAL
ENCLOSURE
39-3/4" (1010mm)
37-1/4" (946mm)
35" (889mm)
1"
(25mm)
If the supply voltage is 218 Volts or greater, skip
Section 1.6.10, and proceed per Section 1.6.11.
If supply voltage is less than 218 Volts, proceed
per Section 1.6.10.
1 HP
CIRCUIT
BREAKER
FIG. 1.6.6 ELECTRICAL:
QC-40
– TOP VIEWModel
–
ENSURE THE AVAILABLE POWER
SOURCE MATCHES THE VOLTAGE
STAMPED ON UNIT NAMEPLATE
1.6.11 Make certain the branch circuit breaker (main
panel) and Quickchiller circuit breaker (see
figure 1.6.6 - accessible thru front grille; grille
need not be removed) are in their OFF position.
Also make certain the available power matches
the Quickchiller power requirements.
1.6.12 Complete electrical connections to the
Quickchiller.
1.6.7 All electrical connections have been made
and tested by the factory. It is necessary to
hard wire the cabinet by installing the proper
power cord and making connections (3 wire,
L 1 , L 2 , and GND [ EARTH ] ) in the electrical box
located at the back of the unit. See Fig. 1.6.6.
1.6.8 Before making the electrical connection read
Section 1.6.9 thru 1.6.11 and refer to the
electrical schematic.
1.6.9 The Quickchiller utilizes a 24 Volt control
system with step-down transformer. The
primary side of the transformer is factory wired
for a 240 Volt power supply. Check the supply
voltage on the branch circuit servicing the
Quickchiller.
Following electrical installation,
additional steps are necessary to prepare the control for operation.
PG .
4
#8402 QC-40
INSTALLATION
&
MAINTENANCE MANUAL
2.0 — Control Set-Up and Operation
2.1 START-UP PROCEDURES
remains in the display longer than 60
seconds, the locked control panel cover
must be opened and the yellow reset
button pressed ONCE. Relock the control
panel and enter the correct password to
gain access to the User Setting Menu
screen.
2.1.1 Place the branch circuit breaker (main
panel) in the ON position. Then place the
Quickchiller circuit breaker in the ON
position.
2.1.2 The Main Menu screen must appear on
the Control display (see figure 2.1.3). If
the Main Menu screen appears, skip
Sections 2.1.3 thru 2.1.5 and proceed with
SET-UP per Section 2.2. If the Main Menu
screen does not appear, proceed with
Section 2.1.3.
N OTE : T WENTY- FOUR (24) HOUR TIME
M ILITARY TIME IS REQUIRED .
1:00 PM = 1300 M ILITARY TIME
2.2.3
Select option "B" and set the
correct time and date.
Following entry, press "C," immediately
followed by "D" to return to the Main
Menu screen. ( FOR ADDITIONAL
INFORMATION SEE BOOKLET NO . 265,
Quickchiller Operating Procedure Guide,
SECTION 7.0 USER SET- UP.)
N O T E : B A C K - U P B AT T E R Y P O W E R
The Quickchiller control back-up battery is
fully charged prior to Quickchiller shipment
and will maintain control memory for
approximately fourteen (14) days.
2.1.3 The control display will show "SYSTEM
INITIALIZED" and an audible alarm will
sound for 30 to 60 seconds. Leave the
unit alone for two (2) minutes.
2.2.4 Press and hold the "1" button on the
keyboard for a period of five (5) seconds.
The Software Version screen will appear.
Quickchiller Model QC-40 must appear. If
Model QC-40 appears, proceed with
Section 2.3. If Model QC-40 does not
appear, proceed with Sections 2.2.5
through 2.2.7.
2.1.4 Turn the Quickchiller circuit breaker OFF.
Leave the unit OFF for 30 seconds.
2.1.5 Turn the Quickchiller circuit breaker ON
again. The Main Menu screen on the
display should now appear.
2.2.5 Press and hold zero (0) button again
until Password Entry screen appears.
Enter password number on the
numerical keyboard.
2.2 SET-UP
2.2.1 Make certain the main menu appears on
the control display (LCD) when power is
supplied to the unit.
Password
16021892
Press "D" Button to access Set-up Menu
Screeen.
2.2.2 Access the Password screen: Press and
hold the "0" button on the keyboard for a
period of 5 seconds. When the Password
Entry screen is in view, enter the password
number on the numerical keyboard.
2.2.6 Select option "C" and set correct Chiller
Model to "QC-40" using the "C" button.
Following entry, press "D", and press "D"
again to return to Main Menu screen.
PASSWORD
Password
5588744
5588744
2.2.7 The QC-40 is now ready for operation.
Following password entry, press "D" on
the keyboard to access the User Setting
Menu screen. If the wrong password
number is entered in error, "Access
Denied" will appear in the display. If it
#8402 QC-40
INSTALLATION
OR
FOR A COMPLETE AND COMPREHENSIVE GUIDE
TO THE OPERATION OF THE QUICKCHILLER SEE
BOOKLET NO. 265,
Quickchiller Operating Procedure Guide
&
MAINTENANCE MANUAL
PG .
5
2.0 — Control Set-Up and Operation
MICROPROCESSOR CONTROL
®
™
QUICK CHILL ...................
HOLD FOOD .....................
DEFROST FOOD ...............
PRINT REPORT.................
—
0
CE
The Alto-Shaam ® Quickchiller ™ includes a
microprocessor control panel which utilizes a menu
screen to guide the operator through all operation
mode sequences.
A
B
C
D
MENU SCREEN
— MAIN MENU SHOWN
A
B
C
D
CONTROL KEYBOARD
CHILLING or HOLDING
1. LOAD FOOD. IF A PRINTOUT IS REQUIRED OR
IF "AUTO-CHILLING" INSERT PRODUCT PROBES.
2. SELECT MODE OF OPERATION "A" OR "B" FROM
THE MENU, THEN FOLLOW PROMPTS.
DEFROSTING
1. REMOVE FOOD FROM UNIT.
2. SELECT MODE "C" FROM MENU, THEN
FOLLOW PROMPTS.
QUICK REFERENCE OPERATION GUIDE
NOTES:
• THE UNIT WILL PERIODICALLY AUTO-DEFROST
WHILE HOLDING.
• REFER TO THE OPERATION MANUAL FOR MORE
DETAILED INFORMATION.
Fig. 2.1.3
2.3 START-UP TEST
2.3.1 With the chiller door closed, test the door
buzzer and door switch by entering the hold
cycle. Press "B" on the keyboard when the
Main Menu screen appears on the display.
The compressor will become audible. After a
period of 60 seconds, open the unit door. A
buzzer should sound and the display will
prompt the operator to close the door.
decrease of the temperatures appearing in the
display. The temperatures displayed should
start at the approximate room temperature and
decrease from that point. If any of the
temperatures displayed are above 120°F
(49°C), considerably above normal room
temperature, contact the Alto-Shaam Service
Department.
2.3.2 Close the door and allow the unit to operate
for approximately 10 minutes. Verify the
operating time with the timer which appears
in the upper right-hand corner of the Hold
Mode display screen. If the timer does not
indicate the correct amount of time, begin the
SET-UP procedure once again.
2.3.4 Following the 10 minute test operation period,
press "D" on the keyboard to exit the hold
mode. Open the unit door and make certain
the interior walls of the unit are cold.
2.4 SEQUENCE OF CONTROL OPERATION
2.4.1 Refer to Tables 2.4.1 and 2.4.2 for an overview
of control operations. For more information,
refer to booklet No. 265, Quickchiller Operation
Procedure Guidelines.
2.3.3 With the food probe(s) remaining in the
appropriate holder (no product) verify a
PG .
6
#8402 QC-40
INSTALLATION
&
MAINTENANCE MANUAL
2.0 — Control Set-Up and Operation
CONTROL MODE OVERVIEW
Ta b le 2.4.1
Mode
Operation Description
Auto Chill Refrigeration is controlled only by the food probe(s). Refrigeration continues
until all food probes achieve chill setpoint temperature, whereupon the control
automatically enters HOLD Mode.
Timed Chill Refrigeration is controlled by chill time entered and the cabinet air sensor. While
chilling, the cabinet air temperature may become exces-sively cold prior to chill
time expiration. The cabinet air sensor will then cycle the refrigeration system
OFF and ON, at cabinet air temperatures of 15°F (-9°C) and 20°F (-7°C)
respectfully, until chill time expiration. The control automatically enters Hold
Mode upon chill time expiration.
Hold Refrigeration is controlled by the cabinet air sensor only.
Auto Defrost Only the evaporator coil defrost heaters are operational with a 20 minute time
limit. A coil mounted defrost heater terminator switch (thermal) limits the
coil temperature to 60°F (15°C) maximum until 20 minutes expire. Auto
Defrost occurs automatically after six (6) hours of continuous evaporator fan
operation. The six hour "count-up" is overridden in either Chill Mode.
Manual Defrost Can only be selected in the HOLD Mode. See Auto Defrost for operation.
Upon completion of a manual defrost, the Quickchiller
will not automatically default to the Hold Mode. Control mode selection is
required.
NOTE: For optimum performance, utilize Manual Defrost at the start and end of each service day
Ta b le 2.4.2
EVAPORATOR FAN, DOOR HEATER & CONDENSING UNIT OPERATION
OPERATION SPECIFICS
Evaporator Controlled by door switch and evaporator coil mounted for terminator
switch (thermal).
Fan(s) OFF when door is opened.
OFF with coil temperature above 60°F (15°C) .
ON with coil temperature below 30°F (-1°C) .
Door Heater ON and OFF with evaporator fan(s).
Condensing Unit(s) Controlled by a low pressure switch (cut-out @ 2 PSIG, cut-in @ 18 PSIG).
Upon control mode satisfaction, the liquid line solenoid valve closes to
begin a low side pump-down with condensing unit shutoff at 2 PSIG.
Upon call for refrigeration, the liquid line solenoid valve opens which
increases low side pressure to condensing unit start at 18 PSIG. Refer to
Section 2.7, Shut-Down Procedure for additional details.
NOTE: The RTD sensor(s) mounted to the evaporator coil serves no controlling
purpose and is for displaying coil temperature for reference only.
#8402 QC-40
INSTALLATION
&
MAINTENANCE MANUAL
PG .
7
2.0 — Control Set-Up and Operation
2.5
MAIN MENU
The main menu is the starting point for all
functions of the Quickchiller. This includes
starting the hold, defrost, and chill cycles;
report printing; and changing the system
configuration.
2.5.2 Open Door
If the door is opened while the chiller is in
the hold mode, a buzzer will sound and a
warning message will appear in the display.
DOOR OPEN WARNING SCREEN
There are four main options shown on the
main menu screen. These options are
selected with control keyboard buttons "A"
through "D." The remaining options are
initiated by holding down a number button
for 5 seconds. These options are used to test
the chiller, and to view or change the
configuration of the chiller.
( FOR ADDITIONAL INFORMATION SEE BOOKLET NO .
265, Quickchiller Operation Procedure Guide,
Sections 7 & 8.)
WARNING:
*** UNIT HOLDING ***
PLEASE CLOSE DOOR!
A variation of this warning message will
appear in the display when the door is
opened in any cycle; hold, chill, or defrost.
The precise time the door is opened is
recorded in memory and can be obtained
on a print-out.
MAIN MENU SCREEN
QUICK CHILL . . . . . . . . . . A
HOLD FOOD . . . . . . . . . . . B
DEFROST UNIT . . . . . . . . . C
PRINT REPORT . . . . . . . . . D
2.5.1 Hold Mode
To immediately enter the hold food mode,
press "B" on the keyboard when the Main
Menu screen is displayed.
The unit will activate and the chiller will
bring the cavity temperature within a few
degrees of the hold set-point.
HOLD MODE SCREEN
UPPER:
40F
MID:
38F
L OW E R :
36F
HOLD:
38F
00:20:30
S TO P = D
The labels "UPPER," "MID," and "LOWER" all
refer to the internal food probes. The screen
displays the current temperature of these
probes in either Celsius or Fahrenheit. The
length of time the hold cycle has been active is
shown in the upper right corner of the screen.
PG .
8
#8402 QC-40
INSTALLATION
&
MAINTENANCE MANUAL
2.0 — Control Set-Up and Operation
2 . 6 OPERATION WITH FOOD PRODUCT
Stage 1:
Stage 4:
Prior to introducing product to the cabinet, the
unit should be operated in the timed chill mode
for thirty minutes. This procedure will reduce
the temperature of the interior components and
the cabinet air sufficiently to be able to accept
hot food products.
Upon satisfaction of the Chill Mode selected, the
system will revert to the hold mode.
Stage 5:
Once the system has run through prolonged or
consecutive quick chill cycles, it may be
advisable to place it through a manual defrost.
Stage 2:
The system will automatically defrost in the
hold mode — BUT ONLY IN THE HOLD MODE.
A manual defrost can be initiated and,
depending on unit usage, may be necessary to
maintain proper operation.
Roll the slide-in pan rack into the Quickchiller,
select mode and start operation.
Stage 3:
At a factory adjusted set-point the smaller
condensing unit will cycle OFF allowing the
larger system to continue the temperature
pull down process.
2.7
Adequate spacing must be allowed between
pans for proper air circulation for both the
chilling function and subsequent storage.
SHUT-DOWN PROCEDURE
The Quickchiller can be shut-down at the end
of the production day whenever any menu
screen which includes STOP=D is displayed.
Press "C" on the keyboard to continue shutdown. The Main Menu Screen will appear in
the display.
Before starting unit shut-down, make certain
all product has been removed from the unit.
Press "D" on the keyboard to begin shut-down.
MAIN MENU SCREEN
QUICK CHILL . . . . . . . . . . A
UPPER:
40F
(DONE)
HOLD FOOD . . . . . . . . . . . B
MID:
38F
(DONE)
DEFROST UNIT . . . . . . . . . C
L OW E R :
36F
(DONE)
PRINT REPORT . . . . . . . . . D
HOLD:
38F
S TO P = D
The Quickchiller will be ready for start-up as
required and will be fully operational after
allowing 40 minutes to pre-chill before resuming
operations with product.
The unit will display a Stop Prompt screen as
a safeguard against accidental shut-down.
A R E YO U S U R E ?
For prolonged periods of shut-down, thoroughly
clean and sanitize the interior and exterior of the
unit with a mild detergent diluted in warm
water. Maintain the Quickchiller circuit breaker
and branch circuit breaker (Main Panel) in their
ON positions to preserve control data memory.
If power is terminated for more than fourteen
(14) days, and control data memory is lost, refer
to Control Set-Up and Operation, Section 2.0.
YES . . . . . . . . . . . . . . . . . .C
NO . . . . . . . . . . . . . . . . . .D
NOTE: T h e c o n d e n s i n g u n i t ( s ) w i l l s h u t
o f f i m m e d i a t e l y, b y p a s s i n g t h e
low pressure switch.
N o p u m p - d o w n w i l l o c c u r.
#8402 QC-40
INSTALLATION
&
MAINTENANCE MANUAL
PG .
9
2.0 — Controls, Operation and Start-Up
2.8 HARDWARE NOTES
AT- A - G L A N C E
QC-40 CONTROL SETTINGS
NOTE: Refer to Operation and Procedure Guide, Section 9.0.
SERIAL PRINTER:
PRINTER . . . . . . . . . . . . . . . .
Printer Interface
Baud Rate
Stop Bits
Printing Delay
Sample Period, min.
Print Grid Spacing
Print Grids
Printer Columns
BUZZERS/TIMEOUTS . . . . . . .
Probe Mute Time, sec.
Chill Done Time, sec.
Are-U-Sure Time, sec.
DefrstDone Time, sec.
Probe Mute Buzzer
Chill Done Buzzer
Are-U-Sure Buzzer
Defrost Done Buzzer
HOLDING . . . . . . . . . . . . . . . .
Hold Set-point, C
Hold Offset, 0.1C
Hold Low Offset, 0.1C
Hold Med Offset, 0.1C
HoldHigh Offset. 0.1C
CHILLING . . . . . . . . . . . . . . . .
Probe 1 Set-point, C
Probe 2 Set-point, C
Probe 3 Set-point, C
Chill Set-point, C
Chill Offset, 0.1C
ChillLow Offset. 0.1C
ChillMed Offset, 0.1C
ChillHi Offset. 0.1C
DEFROSTING . . . . . . . . . . . . .
Automatic Defrost
AutoDefrst Per. 5min
DefrstWarnTime, 10min
Coil1 Defrost End. C
Coil2 Defrost End, C
Defrost Time, min
MISC . . . . . . . . . . . . . . . . . . .
Chiller Model
Compressor Mode
Number Compressors
Power Throttle
Temp Cycling
RTD Offset, 0.1C
Power Down Minutes
Temperature Units
Time Format
Fan Cut-in Temp, C
Fan Cut-Out Temp, C
KeyBoard Buzzer
Device Access Number
The printer MUST have an internal buffer of at least 1K
bytes. Since the printer must be able to maintain the same
pace as the control, and there is no printer handshaking,
printers with smaller buffers simply cannot keep up. The
printer must also conform to RS-232 standards and must
be able to print using only the TX and GND lines (i.e.,
without hardware handshaking or software handshaking
(XON/XOFF). Nearly all serial printers can print without
handshaking. The printer should be connected to the
control with a NULL serial cable.
RECOMMENDED:
Star Micronics PN# DP-8340 FM
Alto-Shaam Serial Printer & Cable Package PN#14218
PARALLEL PRINTER:
Any EPSON, IBM PRO-PRINTER or compatible is acceptable.
The internal buffer should be at least 1K byte. Most of the
newer printers have at least this amount or more. A standard
printer cable is required. It is not necessary to use a printer
with 24 pins or special graphic capabilities. Alto-Shaam
Parallel Printer Cable (part number 14709) is recommended to
connect parallel printer to Quickchiller control .
DIP SWITCH:
The dip-switch is located on the CPU board. It is read by the
software each time the main menu is entered. Changing the
settings while at the main menu will not effect a change until
the main menu is exited and reentered.
When taking advantage of the special feature program options,
we strongly recommend
FIG. 2.8 - CPU BOARD
individuals with an electronics
(PARTIAL VIEW)
DIP-SWITCH LOCATION
background to properly locate
and change dip-switch position.
Refer to Operation and Procedure
Guide, Section 8.1.
FUNCTION
OFF
ON
1
Language ENGLISH SPANISH
2
Reserved
—
—
3
Reserved
—
—
4
On-Line Print
NO
YES
5
Reserved
—
—
1 2 3 4 5
SWITCH
NUMBER
DIP-SWITCH
BUZZER
NOTE: [ ] =
PG .
10
#8402 QC-40
INSTALLATION
&
DEFAULT VALUES
MAINTENANCE MANUAL
...
=
=
=
=
=
=
=
=
...
=
=
=
=
=
=
=
=
...
=
=
=
=
=
...
=
=
=
=
=
=
=
=
...
=
=
=
=
=
=
...
=
=
=
=
=
=
=
=
=
=
=
=
=
..............
Serial
4800
1 bit
40
[40]
5
[ 5]
5
[ 5]
YES
[40]
..............
30
[30]
60
[60]
20
[20]
60
[60]
0
[ 0]
1
[ 1]
2
[ 2]
3
[ 3]
..............
3
[ 3]
0
[ 0]
6
[ 6]
4
[ 4]
4
[ 4]
..............
4
[ 4]
4
[ 4]
4
[ 4]
-10
[- 6]
0
[ 0]
8
[ 8]
8
[ 8]
8
[ 8]
..............
YES
72
[72]
60
[60]
16
[16]
16
[16]
20
[20]
..............
QC-40
CPU CNTR
TWO
YES
YES
0
[ 0]
1
[ 1]
Farhen
HH:MM
4
[ 4]
13
[13]
ON
49
[49]
5.0 — Cleaning & Maintenance
5 . 1 INTRODUCTION
To insure trouble free operation and the highest level of sanitation control, periodic cleaning and
maintenance is required. The maintenance system should be aimed at maximizing the efficient
utilization of maintenance personnel, minimizing down time, and providing the orderly acquisition
of spare parts for support. If already established at the location site, perform scheduled
maintenance in accordance with the standards in the Maintenance Index Plan.
The Alto-Shaam® Quickchiller should be cleaned and sanitized a minimum of once a week.
Good equipment that is kept clean works better and lasts longer. Protect your investment.
Always follow appropriate state or local health (hygiene) regulations regarding all applicable cleaning and
sanitation requirements for equipment.
WA R N I N G
!
!
D E A C T I VAT E T H E S Y S T E M B Y
D I S C O N N E C T I N G T H E P O W E R S U P P LY
BEFORE PERFORMING ANY CLEANING OR
M A I N T E N A N C E W H I C H I N V O LV E S P L A C I N G
H A N D S N E A R M O V I N G PA RT S .
5.2
5 . 3 EXTERIOR CLEANING
INTERIOR CLEANING
Disconnect unit from power source. Remove
the slide-in pan rack and rack-track and leave the
door open to warm the interior of the cabinet.
Disconnect unit from power source.
1. Wipe all exterior surfaces including the control
panel, door frame, latches, and hinges with a damp
cloth containing a mild, non-abrasive detergent
solution without chlorine. Rinse with cloth and
warm water Allow to air dry.
1. Remove any loose food debris from cabinet with a
cleaning cloth or small hand broom.
2. Wipe down the interior of the cabinet with a
damp cloth and any good alkaline or
alkaline chlorinated based commercial
detergent or grease solvent at the
recommended strength. Use a plastic
scouring pad for difficult areas. Avoid the
use of abrasive cleaning compounds,
chloride based cleaners, or cleaners
containing quaternary salts.
2. To help maintain the protective film coating on
polished stainless steel, clean the exterior with a
cleaner recommended for stainless steel surfaces.
Spray the cleaning agent on a cloth and wipe with
the grain of the stainless steel.
Be sure to clean the ceiling, foor, walls and fan
panel. Clean the vinyl gaskets and the interior
door panel. Make certain to clean under the
gaskets to remove any mildew accumulation or
food residue.
3. Avoid an accumulation of oil based polish or cleaner
collecting along the edges of the keyboard overlay
on the control box. Oil build-up around the control
overlay could eventually loosen the panel.
5 . 4 SLIDE-IN PAN RACK
AND RACK TRACK CLEANING
1. Clean, using a brush, damp cloth and any good
alkaline or alkaline chlorinated based commercial
detergent or grease solvent at the recommended
strength.
3. Rinse everything with clean water and cloth to
remove all residue. Allow cabinet interior to air dry
with the door open.
2. Hand wipe all framing and pan rails. Thoroughly
clean debris from the wheels. A spray hose can be
used for easier rack cleaning. Rinse with warm water.
CAUTION
DO NOT USE SPRAY OR PRESSURE HOSE
CLEANING TECHNIQUES ON THE
EXTERIOR OR INTERIOR OF THE
CABINET. WATER DAMAGE CAN
OCCUR TO THE CONTROL SYSTEMS.
#8402 QC-40
INSTALLATION
4. Wipe or spray with a sanitizing solution designed
for use on metal and vinyl food contact surfaces.
5. Allow to air dry.
&
MAINTENANCE MANUAL
PG .
11
5.0 — Cleaning & Maintenance
5.6 MONTHLY COMPRESSOR AND
CONDENSER MAINTENANCE
5.5 EVAPORATOR CONDENSATE DRAIN
HOSE INSPECTION AND CLEANING
1. Every 4-6 months, the evaporator coil and
condensate drain hose should be inspected for
blockage due to spilled food and sauces which
can accumulate about the base of the coil and
clog the entrance to the drain hose.
Keep the condenser coils free of dust and
debris to insure proper air circulation and
cooling of the refrigeration system.
1. Turn power supply to the cabinet OFF by
switching the circuit breaker switch on the
main breaker panel to the OFF position.
Remove the front grille.
2. With the Slide-In-Pan-Rack and Rack Track
removed, remove the two screws at the bottom
sides of the storage compartment. Remove the
cover to expose the evaporator coil. Inspect the
base of the coil for food spillage, condensate
pooling and evaporator coil ice. If this area is
free of contaminants, cleaning is not required.
If cleaning is required, proceed with step 3.
2. Using a vacuum or small hand broom, brush
the condenser coils in a vertical motion to
remove any accumulated dust or debris.
3. Replace air grill and return main circuit breaker
switch to the ON position.
3. To clean the base of the coil and drain hose,
first remove larger food particles by hand.
From the rear of the unit, locate the drain hose,
remove the free end from the condensing unit
drain pan and place it into a bucket. Flush the
base of the coil and drain hose with very hot
water until clean.
4. Return the free end of the drain hose to the
condensing unit drain pan.
5. Re-install the cover and screws.
WA R N I N G
!
!
D E A C T I VAT E T H E S Y S T E M B Y
D I S C O N N E C T I N G T H E P O W E R S U P P LY
BEFORE PERFORMING ANY CLEANING OR
M A I N T E N A N C E W H I C H I N V O LV E S P L A C I N G
H A N D S N E A R M O V I N G PA RT S .
PG .
12
#8402 QC-40
INSTALLATION
&
MAINTENANCE MANUAL
R a c k M a n a g e m e n t Tr o l l e y S y s t e m
1 0 • 1 0 C o m b i t h e r m a n d 1 0 • 1 8 W Wa r m e r
7
1
2
6
5
3
8
4
10
9
11
17
14
13
12
ON
F
OF
16
ON
F
OF
15
FIG. 1.4.1
DESCRIPTION
QUAN.
PT. NO.
Pan Rack Assembly
1
15637
1.
Base Frame
1
14584
2.
Handle Assembly
1
3.
Wheels
4.
DESCRIPTION
QUAN.
PT. NO.
Base Trolley Assembly
1
15635
9.
Guide Block
1
BK-23020
14184
10.
Guide Screw
2
SC-2713
4
WH-23034
11.
Lock Assembly
1
14580
Wheel Axis
4
WH-23035
12.
Support Brace
1
12927
5.
Wheel Screw
4
SC-23868
13.
Brace Screw
2
SC-2425
6.
Pan Lock
2
LK-23065
14.
Lever Knob
1
KN-23047
7.
Lock Screw
2
SC-22268
15.
Locking Caster
2
CS-23050
8.
Rack Track Assembly
1
14581
16.
Plain Caster
2
CS-23051
17.
Base Assembly
1
14579
N OTE :
QC-40
FOR
Q UICKCHILLER M ODEL QC-40,
REFER TO
SERVICE PARTS LIST FOR RACK TRACK PART NUMBER .
#8402 QC-40
INSTALLATION
&
MAINTENANCE MANUAL
PG .
13
R a c k M a n a g e m e n t Tr o l l e y S y s t e m
7 • 1 4 C o m b i t h e r m a n d 1 0 • 1 8 W Wa r m e r
7
1
2
6
5
3
4
8
10
9
11
17
14
13
12
ON
F
OF
16
ON
F
OF
15
FIG. 1.4.2
DESCRIPTION
QUAN.
PT. NO.
Pan Rack Assembly
1
15639
1.
Base Frame
1
14586
2.
Handle Assembly
1
3.
Wheels
4.
DESCRIPTION
QUAN.
PT. NO.
Base Trolley Assembly
1
15635
9.
Guide Block
1
BK-23020
14184
10.
Guide Screw
2
SC-2713
4
WH-23034
11.
Lock Assembly
1
14580
Wheel Axis
4
WH-23035
12.
Support Brace
1
12927
5.
Wheel Screw
4
SC-23868
13.
Brace Screw
2
SC-2425
6.
Pan Lock
2
LK-23962
14.
Lever Knob
1
KN-23047
7.
Lock Screw
2
SC-22268
15.
Locking Caster
2
CS-23050
8.
Rack Track Assembly
1
14582
16.
Plain Caster
2
CS-23051
17.
Base Assembly
1
14579
N OTE :
QC-40
PG .
14
FOR
Q UICKCHILLER M ODEL QC-40,
REFER TO
SERVICE PARTS LIST FOR RACK TRACK PART NUMBER .
#8402 QC-40
INSTALLATION
&
MAINTENANCE MANUAL
R a c k M a n a g e m e n t Tr o l l e y S y s t e m
1 0 • 1 8 C o m b i t h e r m a n d 1 0 • 1 8 W Wa r m e r
1
7
6
2
5
3
4
8
10
9
11
17
14
13
12
ON
F
OF
16
ON
F
OF
15
FIG. 1.4.3
DESCRIPTION
QUAN.
PT. NO.
Pan Rack Assembly
1
15638
1.
Base Frame
1
14585
2.
Handle Assembly
1
3.
Wheels
4.
DESCRIPTION
QUAN.
PT. NO.
Base Trolley Assembly
1
15635
9.
Guide Block
1
BK-23020
14184
10.
Guide Screw
2
SC-2713
4
WH-23034
11.
Lock Assembly
1
14580
Wheel Axis
4
WH-23035
12.
Support Brace
1
12927
5.
Wheel Screw
4
SC-23868
13.
Brace Screw
2
SC-2425
6.
Pan Lock
2
LK-23029
14.
Lever Knob
1
KN-23047
7.
Lock Screw
2
SC-22268
15.
Locking Caster
2
CS-23050
16.
Plain Caster
2
CS-23051
17.
Base Assembly
1
14579
8. Rack Track Assembly
N OTE :
QC-40
FOR
1
Q UICKCHILLER M ODEL QC-40,
14582
REFER TO
SERVICE PARTS LIST FOR RACK TRACK PART NUMBER .
#8402 QC-40
INSTALLATION
&
MAINTENANCE MANUAL
PG .
15
3.0 — Control & Component Parts Identification
3 . 1 — Q C - 4 0 C O N T R O L PA R T S L I S T, s e e p a g e 1 3
ITEM
DESCRIPTION
QUAN.
PT. NO.
CPU ENCLOSURE ASSEMBLY
1
15034
1.
LCD Board Assembly
1
BA-33304
2.
Door Lock
1
LK-23046
3.
Door Gasket
5.
Buzzer
6.
Dip Switch
7.
EPROM
8.
PFI Adjust, P12
9.
Write Protect Jumper
4' (1219mm)
10.
I/O Cable
11.
J10 "—" Pin
12.
CPU Board
13.
Keys, Door Lock
1
GS-2019
BA-33100
LK-24176
3 . 2 — Q C - 4 0 E L E C T R I C A L PA R T S L I S T, s e e p a g e 1 4
ITEM
DESCRIPTION
QUAN.
PT. NO.
1.
Filter-EMF
1
FI-3580
2.
Compressor Fuse Blocks-15A ( U P P E R )
1
FU-3772
— Fuses, 15A, Glass G
2
FU-3775
Compressor Fuse Block-20A (lower)
1
FU-33239
— Fuses, 20A, Class G
2
FU-33042
3.
Terminal Block, 3 Pole
1
BK-33111
4.
24 Terminal Connector Block Assembly
1
15069
6.
Transformer
1
TN-33480
7.
Heat Sink (Self-contained Only)
2
HE-23421
8.
Relay (Self-contained Only)
2
RL-33246
9.
Relay Board
1
BA-33099
10.
30A Circuit Breaker (On/Off)
1
SW-3715
11.
Relay Varister (Self-Contained Only)
2
RS-3578
12.
Defrost Heater
1
Cosp RWDH02
13.
Defrost Heater Terminator Switch
1
Cosp RWE056
14.
Door Heater
1
Cosp L2HR110
15.
Door Switch Magnet
1
MA-3739
16.
Door Switch
1
SW-33580
17.
Fan Terminator Switch
1
RWE056
2A.
3.3 — QC-40 PROBES AND SENSORS
DESCRIPTION
PG .
16
QUAN.
PT. NO.
72" (1829mm) Food Probe Assembly
3
PR-3850
Cold Tube Sensors, 1-3/4"
3
14786
Sensor Mounting Block
1
#8402 QC-40
INSTALLATION
&
MAINTENANCE MANUAL
BK-22636
#8402 QC-40
INSTALLATION
&
MAINTENANCE MANUAL
PG .
®
DWN BY:
LRP
MENOMONEE FALLS, WISCONSIN, U.S.A.
REV:
SCALE:3/8" = 1"
10/31/95
DATE:
Quickchiller™ Processing Refrigeration System
FIG. 3.1
CPU ENCLOSURE #15034
MODEL:
ITEM:
17
3.0 — Control & Component Parts Identification
2
8
7
4
GND +5V
SWITCH
DOOR
CABLE
I/O
L1
+5 VDC
NC
CPU
COMPRESSOR
POWER
SC-15
BUSS
FUSE
POWER IN
1
24 VAC
RELAY
2A
2
LH
OUTPUT
CRYDOM
L1
ASSEMBLED
IN MEXICO
10104
A2425
RH
INPUT
4
4
1
3-4
5-6
L1
3-4
5-6
L1
1
3
6
RIGHT HAND FANS
1-2
LINE
LEFT HAND FANS
LOAD
2X.0047uF +20%/25% (Y)
C-3X1uF(X2)MP/MKT
L-2X(1.86+1.86) mH
R-1X1M OHM
LINE
CURTIS
RFI FILTER
F1300AA01
INDUSTRIES INC.
1A/115-250 VAC 50/60 HZ.
1-2
LOAD
L1
HEATERS
2
3
L1
HEATERS
5
SC-20
BUSS
FUSE
6
SC-20
BUSS
FUSE
3
SOLINOID
SC-15
BUSS
FUSE
SOLID-STATE RELAY
9
COMPONENT BOX WITH COVER REMOVED
(Located on back of unit)
Fig. 3.2.1
ITEM:
Component Box Assembly
MODEL: QC 40 Quickchiller Processing Refrigeration System
DATE:
01/18/99
®
MENOMONEE FALLS, WISCONSIN 53051, U.S.A.
PG .
18
#8402 QC-40
INSTALLATION
&
MAINTENANCE MANUAL
3.0 — Parts Identification
3.4 — QC-40 - REFRIGERATION PARTS LIST
ITEM
DESCRIPTION
QUAN.
PT. NO.
1.
Large Condensing Unit
1
Cosp RUT910
2.
Small Condensing Unit
1
Cosp RUT550
3.
Filter Dryer
2
Cosp RWFD02
4.
Sight Glass
2
Cosp RWSG03
5.
Solenoid Valve
2
Cosp RWSV03
6.
Solenoid Coil
2
Cosp RWSC02
7.
Evaporator Coil
1
Cosp RWE311
8.
Evaporator Blower Motor
3
MO-33670
9.
Expansion Valve (1/4 ton)
1
Cosp RWEV27
10
Expansion Valve (1/2 ton)
1
Cosp. RWEV30
3.5 — QC-40 CABINET & MISCELLANEOUS PARTS
ITEM
DESCRIPTION
QUAN.
PT. NO.
1.
Slide-In Pan Rack
1
15638
2.
Shelves
5
SH-22584
3.
Base Trolley (optional)
1
15635
4.
Rack Track
1
Cosp FQRC02S
5.
Rack Track Pan
1
Cosp FQRC06S
6.
Front Grille Assembly
1
14700
7.
Leg, Adjustable, 6"
4
Cosp HLEG63
8.
Door Handle
1
HD-2934
9.
Door Latch
1
LT-2935
10.
Door Hinge
2
HG-22111
11.
Door Gasket
1
Cosp GX08MV
12.
Door Assembly (LH hinge)
1
Cosp QDD60SL
13.
Door Assembly (RH hinge)
1
Cosp QDD60SR
#8402 QC-40
INSTALLATION
&
MAINTENANCE MANUAL
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4.0 — Diagnostic and Repair Procedure — CONTROL
4.1
INTRODUCTION
4.2.1 SOLENOID CHECK:
The relays, which control the compressors, fans,
solenoids, and heaters, can be individually controlled
by the microprocessor control set in a manual mode.
The following test will verify that these components
are being controlled and will verify the operational
integrity of the relays and fuse sets.
4.2
Press button 1 and button 2 on the numeric keyboard
several times. Each time these buttons are pressed the
sound of the solenoids should be audible as they click
open and closed. There should also be a distinct
difference in the sound of an opening solenoid and a
closing solenoid.
4.2.2 FAN CHECK:
Under normal operating conditions the fan(s) stop
rotating whenever the chiller door is opened. Fan
operation can only be verified with an open door in
the manual mode. The evaporator coil temperature
must also be below 30°F. Press button 3 followed by
button 4 and open the Quickchiller door. The fans
should be operating.
CONTROL DIAGNOSIS
The main menu is the starting point for this test. With
the Main Menu screen displayed, press and hold "0"
on the numeric keyboard for approximately 5 seconds
to access the password screen.
PASSWORD ENTRY SCREEN
4.2.3 DEFROST HEATER CHECK:
Press button 5, 6, and button 7 once to detect the
sound of the defrost heater relays as they click ON.
Press each of these buttons once again to deactivate
the defrost heaters. This procedure will only detect
the coil side of each of the defrost heater relays but
does not test the operational condition of the defrost
heaters nor test the defrost heater fuses.
Q-CHILLER CONFIGURE
P A S S W O R D : ________________
When the Password Entry screen is in view, enter the
password code on the alphanumeric keyboard.
4.2.4 CONDENSING UNIT CHECK:
Press button 8 once to power both condensing units.
The "compressor" relays are solid-state and will not
produce an audible click, however; the compressors
should be audible. After a short period of time, the
compressors will automatically cycle OFF. Open the
solenoids (see 4.2.1) and the compressors will again
cycle ON. Close the solenoids.
PASSWORD
91095340D
If the wrong password number is entered in error, a
buzzer will sound and the display will revert to the
Main Menu screen. Access the Password Entry screen
again and enter the correct password number.
4.2.5 COOLING TEST:
A correctly entered password will result in a
diagnostic screen.
DIAGNOSTIC SCREEN
SOLEND1=HLD
2=CHL
FA N S
3=HLD
4=CHL
H E AT E R
5=HLD
6, 7=CHL
COMPRS
8=ALL
9, 0, D
Pressing the numerical keyboard numbers 1 through 8
will toggle the power to an individual relay. Buttons 1
and 2 represent the two solenoid relays, while buttons
3 and 4 control the relays for each of the two fan
banks. Buttons 5, 6, and 7 control the three relays
which con-trol each pair of heater wraps. Button 8
controls two relays, each of which controls a single
condensing unit.
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#8402 QC-40
INSTALLATION
Open both solenoids (see 4.2.1) to activate the
compressors. When the compressors are activated,
press button 9. The display screen will indicate the
temperature of the air probe, the three food probes,
and the evaporator sensor. Allow the chiller to
operate in this mode for approximately 10 minutes.
The air temperature inside the food storage
compartment should begin to fall. This cooling
condition will be indicated on the display screen. If
the food probe(s) do not appear to be functioning
properly, hold the tip of the probe in your hand. The
temperature display for the hand-held probe should
slowly increase. Any of the probes which display an
excessively high reading (~300 to 400F —149 to 204C)
will indicate a broken connection or defective probe.
Do not allow the unit to operate
unattended in this Mode. This is an
uncontrolled Cool-down Mode and will
eventually cause excessive build-up on
the Evaporators.
&
MAINTENANC
4.0 — Diagnostic and Repair Procedure — CONTROL
4 .3 CONDENSING UNITS
The condensing units operate only when the
system is in a cooling mode and the food storage
compartment requires a decrease in temperature.
If it appears the condensing units are not
functioning properly and the General Diagnostic
Procedure (4.2.4) on the preceding page was
unable to pinpoint the specific cause, the
following steps should be taken for further
diagnosis.
Each of the two compressors have one fuse on
L 1 and L 2 for a total of four fuses. Test each
fuse with an ohm-meter and replace if
necessary only with an identical fuse.
If the fuses do not require replacement or if
the compressors still do not function, call the
factory for assistance.
4.4 FANS, HEATERS, SOLENOIDS
4.3.1 CONTROL CABLE CONNECTIONS:
If it appears the fans, heaters, or solenoids are
not functioning properly and the General
Diagnostic Procedure on the preceding page was
unable to pinpoint the specific cause leading to
repair, follow general directions prescribed for
CONTROL CABLE CONNECTIONS and
CONDENSING UNIT FUSES under the
Condensing Unit heading on this page.
Open the key lock on the alphanumeric
keyboard display enclosure. Inspect each
circuit board connection wire to be certain
they are firmly attached to the board. Pay
particular attention to the gray ribbon cable
which originates through a hole behind the
circuit board. This cable should be firmly
attached to the black connector marked I / O
CONNECTOR . The additional gray ribbon cable
originating from the display should be firmly
attached to the black connector marked LCD
DISPLAY . The black connector marked PRINTER
should only be connected if the original
factory order specified a parallel printer port
instead of the normal serial printer port.
If it is determined the control cable
connections are secure, the problem may be
related to a fuse, relay, or device failure. At
this point in the diagnosis check the fuses.
4.3.2 CONDENSING UNIT FUSES:
Quickchiller condensing units, fans, heaters,
and solenoids are fused with 20mm fuses.
Fuses are located on the relay board which is
mounted within the electrical enclosure.
WARNING
MAKE CERTAIN THE MAIN POWER IS
OFF BEFORE SERVICING.
Disconnect main incoming A.C. power to the
unit. When all power to the system is OFF ,
gain access to the electrical enclosure and
remove the enclosure cover. Before removing
the fuses, measure the voltage to make certain
the power has been completely disconnected.
#8402 QC-40
INSTALLATION
&
MAINTENANCE MANUAL
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4.5 TROUBLE-SHOOTING GUIDELINES - CONTROL
PROBLEM
POSSIBLE CAUSE
Alphanumeric display is blank.
If power is connected to the unit and the
main circuit breaker is on, the display on
the control should be illuminated with a
green tinged background.
Control needs to be reset.
Unresponsive control.
If the control does not respond to operator
key presses or the screen on the display
appears frozen or sluggish.
Control needs to be reset.
Power failure threshold is set too low.
Control board is faulty.
Control not receiving correct power.
If the green light located on the middle
bottom edge of the circuit board is not
illuminated.
Power Failure Threshold is set too low.
POSSIBLE SOLUTION
Press the yellow reset button located within the
locked keyboard door.
Control not receiving correct power.
Power failure threshold is set too low.
Control board is faulty.
Press the yellow reset button
1. Check connector J12 to the right of light along with
other three connecting wires for secure connections.
Loose connection
Control transformer incorrectly wired.
The control continuously measures a fraction of the
input power supplied to the unit. When this
fraction drops below 1.25 - 1.30 Vdc (converted to
DC) the control determines power is on the verge
of failing, saves all important data to battery
memory back-up, and prepares for a power failure.
2. Check the AC voltage across the two end wires on
the connector with a voltmeter for a reading of 22 to
26 VAC. If there is no voltage or the voltage appears
low, check power connector on the relay board inside
electrical enclosure. Also check electronic filter,
transformer, and the two fuses at the bottom of relay
board. See installation instructions.
Turn the trim-pot screw to adjust the amount of input
power used by the control to determine power failure.
1. Open the locked keyboard and locate the blue
trim-pot marked P12 just above the battery at the
bottom of the circuit board.
2. Place voltmeter red lead on the pin-connector
marked J22 (PFI) approximately 5" (127mm) under
the blue trim-pot.
3. Place voltmeter black lead on the metal nut in the
center of the board.
5. Adjust the trim-pot with a screwdriver until the
voltage of the DC-Voltmeter reads 1.70 to 1.85
volts.
Electronic control operates but fans, heaters,
and solenoids are not getting power.
No power to the relay board.
If all or a portion of the four green lights on
the relay board are not illuminated.
Check connections on both ends of the control cable.
Make certain there is power to the relay board.
Relay board may not be receiving full power.
One of the power supplies on the relay board may
not be functioning.
Check connections.
The power cable between the electronic control
and the relay board may not be properly connected
Check the transformer. See installation
instructions.
Check electronic filter.
The control cable between the relay board and the
electronic control may not be properly connected
Control transformer may be incorrectly wired.
Check the coil mounted fan terminator switch.
Excessive chill time.
— Fans not operating.
Check the fan fuses.
Check the connections between the fans and the
relay board.
Manual defrost operational — automatic
defrost does not function.
Verify set-up menu for automatic defrost is set at
YES. See Booklet No. 265, Cook/Chill Operation
and Procedures.
Manual and automatic defrost does not function.
Check heater fuses.
Check the large, transparent, coil-type relays on
the relay board and make certain each relay is
secure in the socket.
Check the control cable for good connections.
Condensing units are not getting power or
Check the over-pressure switch on the pressure
control. This switch opens when an overpressure occurs and must be manually reset.
do not function.
Check the compressor SC15 and SC20 fuses
located in the fuse blocks on the left side-wall on
the inside of the electrical enclosure.
Check for a faulty solid-state compressor relay by
measuring the voltage across the output side of the
relay. If the voltage reads near zero, the relay is
closed. If the voltage reads very close to line
voltage, the relay is open. Open and close these
relays using the diagnostic program (4.2) with a
voltmeter to determine if the relay is opening and
closing.
Display indicates Please Close Door with the
door fully closed.
Adjust the door switch.
Unit will hold at refrigeration temperature but will
not Auto-Chill.
Make certain the food probes are being inserted into
the food BEFORE starting the auto-chill cycle.
PG .
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#8402 QC-40
INSTALLATION
&
MAINTENANCE MANUAL
4 . 0 — D i a g n o s t i c a n d R e p a i r P r o c e d u r e — R E F R I G E R AT I O N
This chart is provided for the assistance of refrigeration technicians only and is not intended for use by
untrained or unauthorized service personnel. If your Alto-Shaam Quickchiller is not operating properly,
check the following BEFORE calling your Authorized Alto-Shaam Service Agent:
➾
Check the power flow to the unit. Fuses OK? Breakers OK?
DO NOT ATTEMPT TO REPAIR OR SERVICE THE QUICKCHILLER BEYOND THIS POINT.
Contact Alto-Shaam for the nearest authorized service agent. These are the only service agents
the company will authorize to repair Alto-Shaam Quickchillers. Repairs made by any other
service agents without prior authorization by Alto-Shaam will void the warranty on the unit.
Compressor does not run
Fixture temperature too high
No electricity..............................Close start or disconnect switch
Refrigerant shortage ..................Evacuate, capture remaining
refrigerant, repair leak,
and recharge.
Fuse blown .................................Replace fuse
Control stuck open ....................Repair or replace
Control set too high ...................Reset control
Frozen compressor .....................Replace
Expansion valve or
strainer plugged.........................Clean or replace
Off on high pressure ..................Determine cause of high
pressure, make corrections, and
reset high limit lock-out.
Expansion valve
out of adjustment .......................Correctly adjust
Unit short cycles
Iced or dirty coil ........................Defrost or clean
Control differential
set too closely.............................Widen differential
Restricted gas lines ....................Clear restriction
Head pressure too low
Discharge valve leaking ............Correct condition
Compressor overload
cutting out ..................................Check for high head pressure
or clogged condenser coil
Refrigerant shortage ..................Evacuate, capture remaining
refrigerant, repair leak,
and recharge.
Shortage of refrigerant ..............Evacuate, capture remaining
refrigerant, repair leak
and recharge.
Unit location too cold ................None needed — efficiency
is increased
Leaky expansion valve ..............Replace
Unit is very noisy
Improper unpacking ..................Remove shipping blocks
and/or angles
Refrigerant overcharge ..............Capture excess refrigerant
Tubing rattle...............................Bend tubes away from point
of contact.
Unit operates long or continuously
Shortage of refrigerant ..............Evacuate, capture remaining
refrigerant, repair leak
and recharge.
Control contacts frozen .............Replace control
Mountings loose.........................Tighten
Frosted liquid line
Receiver shut-off valve
partially closed
or restricted ................................Open valve or remove
restriction
Dirty condenser coil ..................Clean condenser coil
Location too warm .....................Change to cooler location
Plugged expansion valve
R estricted liquid line
or component ...............................Replace restricted part
or retainer ..................................Clean or replace
Iced evaporator coil ...................Defrost or clean
Service load ................................Keep doors closed
Unit on vacuum — frost on expansion valve only
Ice in expansion
valve orifice ...............................Apply hot wet cloth to
expansion valve; moisture
indicated by increase in suction
pressure; replace dryer
Head pressure too high
Refrigerant overcharge ..............Capture excess refrigerant
Dirty condenser coil ..................Clean
Unit location too warm..............Relocate unit
Restricted expansion
valve strainer .............................Clean strainer or replace valve
S P E C I A L I N F O R M AT I O N :
Alto-Shaam, Inc. has a 5-year limited warranty on the Quickchiller ™ compressor. This is
included as standard from the date of the unit shipment. This warranty excludes labor.
#8402 QC-40
INSTALLATION
&
MAINTENANCE MANUAL
PG .
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4 . 0 — D i a g n o s t i c a n d R e p a i r P r o c e d u r e — R E F R I G E R AT I O N
DOOR
SWITCH
I/O
CABLE
LEFT HAND FANS
L1
L1
3-4
1-2
5-6
3-4
HEATERS
HEATERS
1-2
L1
1
2
3
L1
4
SOLINOID
5
6
RH
L1
COMPRESSOR
LH
NC
L1
RELAY
ACCESSORY FUSES
5-6
GND +5V
+5 VDC
CPU
POWER
RIGHT HAND FANS
POWER IN
24 VAC
INDICATOR LIGHTS
I/O PORT
ITEM:
Relay Board
MODEL: QC 40 Quickchiller Processing Refrigeration System
Fig. 4.5.1
DATE:
04/04/97
®
MENOMONEE FALLS, WISCONSIN 53051, U.S.A.
PG .
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#8402 QC-40
INSTALLATION
&
MAINTENANCE MANUAL
INSTALLATION
&
MAINTENANCE MANUAL
4.0 — Diagnostic and Repair Procedure — ELECTRICAL
#8402 QC-40
PG .
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PG .
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INSTALLATION
&
MAINTENANCE MANUAL
4.0 — Diagnostic and Repair Procedure — PIPING
#8402 QC-40
TR ANS P O RTAT I O N
DAMAGE and CLAIMS
LIMITED
WARRANTY
All Alto-Shaam
equipment is sold F.O.B.
shipping point, and
when accepted by the
carrier, such shipments
become the property of
the consignee.
Should damage occur in shipment, it is a matter between
the carrier and the consignee. In such cases, the carrier is
assumed to be responsible for the safe delivery of the
merchandise, unless negligence can be established on the
part of the shipper.
1. Make an immediate inspection while the equipment is
still in the truck or immediately after it is moved to the
receiving area. Do not wait until after the material is
moved to a storage area.
Alto-Shaam, Inc. warrants to the original purchaser that
any original part that is found to be defective in material
or workmanship will, at our option, subject to provisions
hereinafter stated, be replaced with a new or rebuilt part.
The labor warranty remains in effect one (1) year from
installation or fifteen (15) months from the shipping date,
whichever occurs first.
The parts warranty remains in effect one (1) year from
installation or fifteen (15) months from the shipping date,
whichever occurs first.
Exceptions to the one year part warranty period are as listed:
A. Halo Heat cook/hold ovens include a five (5) year
parts warranty on the heating element. Labor will be
covered under the terms of the standard warranty
period of one (1) year or fifteen (15) months.
B.
Alto-Shaam Quickchillers include a five (5) year parts
warranty on the refrigeration compressor. Labor will
be covered under the terms of the standard warranty
period of one (1) year or fifteen (15) months.
2. Do not sign a delivery receipt or a freight bill until you
have made a proper count and inspection of all
merchandise received.
This warranty does not apply to:
1.
Calibration.
3. Note all damage to packages directly on the carrier ’s
delivery receipt.
2.
Replacement of light bulbs and/or the replacement of
display case glass due to damage of any kind.
4. Make certain the driver signs this receipt. If he refuses
to sign, make a notation of this refusal on the receipt.
3.
Equipment damage caused by accident, shipping,
improper installation or alteration.
4.
Equipment used under conditions of abuse, misuse,
carelessness or abnormal conditions.
5.
Any losses or damage resulting from malfunction,
including loss of product or consequential or
incidental damages of any kind.
6.
Equipment modified in any manner from original model,
substitution of parts other than factory authorized parts,
removal of any parts including legs, or addition of any parts.
5. If the driver refuses to allow inspection, write the
following on the delivery receipt:
Driver refuses to allow inspection
of containers for visible damage.
6. Telephone the carrier ’s office immediately upon finding
damage and request an inspection. Mail a written
confirmation of the time, date, and the person called.
7. Save any packages and packing material for further
inspection by the carrier.
8. Promptly file a written claim with the carrier and
attach copies of all supporting paperwork.
We will continue our policy of assisting our customers in
collecting claims which have been properly filed and
actively pursued. We cannot, however, file any damage
claims for you, assume the responsibility of any claims,
nor accept deductions in payment for such claims.
This warranty is exclusive and is in lieu of all other warranties,
expressed or implied, including the implied warranties of
merchantability and fitness for purpose. In no event shall the
Company be liable for loss of use, loss of revenue, or loss of
product or profit, or for indirect or consequential damages.
This warranty is in lieu of all other warranties expressed or
implied and Alto-Shaam, Inc. neither assumes or authorizes
any persons to assume for it any other obligation or liability in
connection with Alto-Shaam equipment.
A LTO - S H A A M , I N C .
Wa r r a n t y e f f e c t i v e J a n u a r y 1 , 2 0 0 0
RECORD THE MODEL AND SERIAL NUMBER OF THE UNIT FOR EASY REFERENCE. ALWAYS REFER TO
BOTH MODEL AND SERIAL NUMBER IN ANY CONTACT WITH ALTO-SHAAM REGARDING THE UNIT.
Model Number: _____________________________________ Date Installed: _____________________________________
Voltage: ____________________________________________ Purchased From: ____________________________________
Serial Number: ______________________________________ ____________________________________________________
W164 N9221 Water Street
PHONE:
●
P. O . B o x 4 5 0
262.251.3800
800.558.8744
FA X :
U. S . A . / C A N A DA
●
Menomonee Falls, Wisconsin 53052-0450
262.251.7067
●
800.329.8744
2 6 2 . 2 5 1 . 1 9 0 7 I N T E R N AT I O N A L
#8402 QC-40 INSTALLATION & MAINTENANCE MANUAL
U. S . A . / C A N A DA
●
U.S.A.
WEBSITE:
W W W. a l t o - s h a a m . c o m
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